Substrate processing apparatus using neutralized beam and method thereof

CROSS-REFERENCE TO RELATED PATENT APPLICATION

0001This application claims the benefit of Korean Patent Application No. 2005-5966, filed on Jan. 21, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND OF THE INVENTION

00021. Field of the Invention

0003The present invention relates to a substrate processing apparatus using a neutralized beam, and more particularly, to a substrate processing apparatus using a neutralized beam thereby maintaining a direction of propagation of an ion source for generating ions and a surface of a substrate in respective positions such that they are perpendicular to each other, and a method thereof.

00042. Description of the Related Art

0005Plasma processing apparatus are commonly used in dry etching processes and in physical or chemical vapor deposition processes. In the plasma processing apparatus, a high-frequency power is applied to a chamber, and, at the same time, reaction gases are supplied into the chamber, so that the reaction gases are dissociated in the chamber to excite plasma by means of glow discharge. Here, ions generated from the plasma are used to perform substrate processing.

0006Meanwhile, integrated circuit design rules have recently been reduced down to 0.1 μm, or less, as semiconductor devices continue to become more highly integrated. As a result, in order to obtain such hyperfine semiconductor devices, processing conditions of the semiconductor processing apparatus have become more critical. Also, performance of the plasma processing apparatus continues to be improved. Such improvements have been primarily obtained through the-techniques of increasing plasma density or equalizing plasma distribution.

0007However, irrespective of the manner in which the performance of the plasma is improved, the plasma has associated specific limitations on basic physical properties thereof. Namely, since the plasma includes charged ion particles, the ions can cause various problems during a process, such as transforming a specific material layer into an amorphous layer, changing a chemical composition of a surface layer of a substrate, generating a dangling bond in a surface layer of a substrate, and causing charge-up damage to an insulating layer of a gate.

0008To solve these problems, a semiconductor processing apparatus using a neutralized beam has been introduced. Namely, a substrate is processed by neutralizing ions generated from the plasma and directing the ions to a surface of a substrate. In different methods of neutralizing ions, the ions can made to collide with neutrons, the ions can be made to collide with electrons, and the ions can be made to collide with a metallic substrate.

0009A technique that employs a metallic substrate for neutralizing ions is disclosed in U.S. Pat. No. 4,662,977, where the metallic substrate is referred to as a neutralizer plate. The angle of the neutralizer plate is controlled, so that the ions can be directed to the substrate by deflecting the ions at a predetermined angle with respect to a scanning direction.

0010When the collided ions are directed to the substrate using the neutralizer plate, however, the angle between a plasma source and the substrate is to be inclined at an angle of the collision. However, it is difficult to maintain such an inclined angle at the time of manufacturing or managing the apparatus. In addition, since the plasma source is inclined, the path of the ions can be altered depending on the plurality of incidence positions. This can lead to a reduction in incidence uniformity.

SUMMARY OF THE INVENTION

0011The present invention provides a substrate processing apparatus using a neutralized beam by colliding ions, which are incident on reflectors on which the ions are neutralized, 2n times (n=positive integer) in symmetrical directions, so that the direction of propagation of the original ion source can be perpendicular to the surface of the substrate to be treated, and a method thereof.

0012In one aspect, the present invention is directed to an etching apparatus comprising: a plasma generating unit; a grid unit that extracts ions from the plasma generating unit and that emits the ions as an ion beam; reflectors at which the ion beam emitted by the grid unit is incident at an incident angle and undergoes a first collision at a collision angle at which the ions are neutralized as a neutralized beam, and at which the neutralized beam undergoes a second collision at the collision angle that restores the neutralized beam to the incident angle; and a substrate stage that mounts a substrate at which the neutralized beam generated from the reflectors is incident to perform substrate processing.

0013In one embodiment, the directions of the first and second collisions are symmetrical to each other.

0014In another embodiment, the incident angle of the ion beam is perpendicular to the surface of the substrate.

0015In another embodiment, the incident angle of the neutralized beam is perpendicular to the surface of the substrate.

0016In another embodiment, the first and second collisions occur 2n (n=positive integer) times in the reflectors.

0017In another embodiment, the collision angle is in a range of about 3° to about 10°.

0018In another embodiment, the reflectors include a plurality of reflecting plates disposed in parallel between the grid unit and the substrate.

0019In another embodiment, the reflecting plates include a first reflecting plate, at which the first collision occurs, and a second reflecting plate, at which the second collision occurs, wherein the second reflecting plate is disposed to face the first reflecting plate.

0020In another embodiment, the reflectors include a first reflector, at which the first collision occurs, and the second reflector, at which the second collision occurs, wherein the second reflector is separated from the first reflector along a direction of ion beam propagation.

0021In another aspect, the present invention is directed to a substrate processing apparatus comprising: an ion source for emitting an ion beam at an emitting angle; reflectors at which the ion beam emitted by the ion source are incident and subject to 2n collisions, where n is a positive integer, in first and second opposite directions to neutralize the ion beam as a neutralized beam and to restore a direction of propagation of the neutralized beam to the emitting angle of the ion beam; and a substrate at which the neutralized beam generated by the reflectors is incident to perform a process.

0022In one embodiment a first collision of the ion beam and a second collision of the ion beam occur in the reflectors in the first and second opposite directions that are symmetrical.

0023In another embodiment, the collisions occur at a collision angle that is in a range of about 3° to about 10°.

0024In another embodiment, the emitting angle of the ion beam and the restored direction of propagation of the neutralized beam are perpendicular to the surface of the substrate.

0025In another embodiment, the ion source includes a plasma generating unit and a grid unit for extracting ions from the plasma generating unit and for emitting the ions as the ion beam.

0026In another embodiment, the reflectors include a plurality of reflecting plates disposed in parallel between the ion source and the substrate.

0027In another embodiment, the reflecting plates include a first reflecting plate, at which a first collision occurs, and a second reflecting plate, at which a second collision occurs, wherein the second reflecting plate is disposed to face the first reflecting plate.

0028In another embodiment, the reflectors include a first reflector, at which a first collision occurs, and a second reflector, at which a second collision occurs, wherein the second reflector is separated from the first reflector along a direction of ion beam propagation.

0029In another aspect, the present invention is directed to a substrate processing method comprising steps of: extracting ions from a plasma to form an ion beam at an emitting angle; neutralizing the ion beam to be a neutralized beam, having a direction of propagation that is aligned with the emitting angle of the ion beam, by colliding the ion beam with reflectors at a collision angle; and processing a substrate by illuminating the neutralized beam onto the substrate.

0030In one embodiment, colliding results in the occurrence of 2n (n=positive integer) collisions in the reflectors.

0031In another embodiment, neutralizing further comprises: first colliding the ion beam to be neutralized to generate a neutralized beam; and second colliding the neutralized beam to restore the direction of propagation thereof to be aligned with the angle of the ion beam prior to the first collision.

0032In another embodiment, the emitting angle of the ion beam and the direction of propagation of the neutralized beam are oriented perpendicular to the substrate.

0033In another embodiment, the collision angle is in a range of about 3° to about 10°.

0034In another embodiment, the step of processing the substrate is an etching process.

BRIEF DESCRIPTION OF THE DRAWINGS

0035The above and other features and advantages of the present invention will become more apparent by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:

0036<figref idref="DRAWINGS">FIG. 1</figref> is a schematic diagram of a substrate processing apparatus using a neutralized beam according to the present invention;

0037<figref idref="DRAWINGS">FIG. 2</figref> is a structural block diagram of the substrate processing apparatus using a neutralized beam according to the present invention;

0038<figref idref="DRAWINGS">FIG. 3</figref> is a view illustrating a state of collision of ions in the substrate processing apparatus using a neutralized beam according to the present invention;

0039<figref idref="DRAWINGS">FIG. 4A</figref> is a view illustrating reflectors of the substrate processing apparatus using a neutralized beam according to an embodiment of the present invention;

0040<figref idref="DRAWINGS">FIG. 4B</figref> is a view illustrating reflectors of the substrate processing apparatus using a neutralized beam according to another embodiment of the present invention; and

0041<figref idref="DRAWINGS">FIG. 5</figref> is a block diagram illustrating a substrate processing method using a neutralized beam according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

0042Hereinafter, a substrate processing apparatus using a neutralized beam according to an embodiment of the present invention will be described in detail with reference to the accompanying drawings.

0043Referring to <figref idref="DRAWINGS">FIG. 1</figref>, the substrate processing apparatus includes an ion source <b>200</b>, reflector unit <b>300</b>, a substrate <b>500</b>, and a substrate stage <b>600</b> on which the substrate <b>500</b> is mounted. Here, the ion source <b>200</b> and the substrate <b>500</b> are disposed to be parallel with each other. In addition, an angle of orientation of the ions, or ion beam, emitted by the ion source <b>200</b> is maintained to be equal to an angle of a neutralized beam which is neutralized by the reflector unit <b>300</b> and is incident on the substrate <b>500</b>.

0044Namely, if an angle at which the ions are emitted to the reflector unit <b>300</b> is perpendicular to a surface of the substrate <b>500</b>, then also the angle that the neutralized beam output by the reflector unit <b>300</b> is incident on the substrate <b>500</b> is implemented to be perpendicular. Here, an implementation of the apparatus of the invention in a perpendicular manner is a goal to be achieved at a schematic design level. In other words, when the apparatus is manufactured in practice, certain errors can occur. Thus, when a perpendicular angle is mentioned in connection with the embodiment of the invention, a certain error range is taken into consideration.

0045Referring to <figref idref="DRAWINGS">FIG. 2</figref>, the embodiment of the present invention will be described in more detail. The substrate processing apparatus includes a chamber <b>100</b> and an ion source <b>200</b> provided in the chamber <b>100</b>. The ion source <b>200</b> includes a plasma generating unit <b>210</b> and a grid unit <b>220</b> disposed at the lower part of the plasma generating unit <b>210</b>.

0046The plasma generating unit <b>210</b> may include an inductively coupled plasma (ICP) that generates a plasma by applying an inductive power, or a capacitively coupled plasma (CCP).

0047The grid unit <b>220</b> includes a first grid <b>211</b>, on which a first though-hole <b>221</b><i>a </i>is formed, and a second grid <b>222</b>, on which a second though-hole <b>221</b><i>b </i>is formed, where both of the grids are operatively coupled to each other. Different voltages are respectively applied to the first and second grids <b>221</b> and <b>222</b>, so that plasma ions can be extracted through the through-holes <b>221</b><i>a</i>, <b>221</b><i>b </i>based on a voltage difference applied to the first and second grids <b>221</b> and <b>222</b>. Meanwhile, although not shown, a third grid can be additionally provided. Here, the third grid is grounded before installation thereof, so that a directional property of the ions can be sufficiently maintained.

0048On the other hand, the ions generated from the grid unit <b>220</b> are generally emitted in a direction that is perpendicular to a surface of the substrate <b>500</b> in the chamber below the grid unit <b>200</b>. Here, the angles of emitted ions may actually have minute differences. In the present invention, however, difference of the emitting angles is taken into consideration whenever a perpendicular angle is mentioned herein.

0049In the lower part of the grid unit <b>220</b>, the reflector unit <b>300</b> is disposed. Referring to <figref idref="DRAWINGS">FIGS. 3 and 4A</figref>, a plurality of reflecting plates <b>310</b>, <b>320</b> having surfaces that are parallel to each other and at a constant interval are disposed to be inclined in the reflector unit <b>300</b>, so that a cross-sectional pattern thereof is generally in the shape of a grill.

0050In one embodiment, the body of the reflector unit <b>300</b> is grounded. In addition, the reflecting plates are made of metal materials, such as tantalum, platinum, molybdenum, tungsten, aurum, and stainless. In another embodiment of the present invention, the reflector unit <b>300</b> may be formed in such a shape that a plurality of inclined holes are formed in a cylindrical tube.

0051In the reflector unit <b>300</b>, the ions propagate along a reflective path such that they each collide 2n times (n=positive integer) in the path. The reflective paths are disposed in parallel with each other as shown in <figref idref="DRAWINGS">FIG. 3</figref> and are formed between the first and second reflecting plates <b>310</b> and <b>320</b> which are disposed to be inclined at a collision angle in a range of about 3° to about 10° relative to the incident direction of the ion beam. In addition, the reflective paths are configured such that the number of ion-collisions for an incident ion is a multiple-of-two times, or 2n (n=positive integer) times.

0052Meanwhile, in a case where the collision angle between the ions and the first and second reflecting plates <b>310</b> and <b>320</b> is less than about 3°, the ion neutralization ratio sharply decreases, while in a case where the collision angle is more than about 10°, unnecessary sputtering can be excessively generated in the first and second reflecting plates <b>310</b> and <b>320</b>. Therefore, it can be understood that the angle in a range of about 3° to about 10° is an adequate collision angle.

0053Hence, the ions first collide with the first reflecting plate <b>310</b> within the reflective path at the angle in a range of about 3° to 10°. Then, the ions are reflected in a direction that is symmetrical to the first collision and collide a second time at the second reflecting plate <b>320</b> at the angle in the range of about 3° to 10°. At the first collision, the ions are neutralized, while at the second collision, the original incidence angle of the ions prior to the first collision with the reflecting plate <b>310</b> is restored. Therefore, the lengths of the first and second reflecting plates of the reflector unit <b>300</b> must be long enough, to ensure that two collisions can be carried out.

0054Referring to <figref idref="DRAWINGS">FIG. 3</figref>, assuming the collision angle of the ions with the reflector unit is θ, the distance between the first and second collisions is L, and the gap between the first and second reflecting plates <b>310</b> and <b>320</b>, or the width of collision path, is W, then the lengths of the reflectors in the reflector unit <b>300</b> can be obtained by the following mathematical equation: sin θ=W/L. Here, the lengths of the reflectors in the reflector unit <b>300</b> are selected to be equal to, or greater than, L and less then 2 L, so that additional collisions can be avoided after the second collision occurs.

0055A theoretical ground of the neutralization is disclosed in the thesis of B. A. Helmer and D. B. Graves, which is titled “Molecular dynamics simulation of C12+ impacts onto a chlorinated silicon surface: Energies and angles of the reflected C12 and C1 fragments” (J. Vac. Sci. Techonol. A 12 (5), Septemper/October 1999).

0056At the lower part of the reflectors <b>300</b>, the substrate stage <b>600</b> disposed to be in parallel to the surface of the grid unit <b>220</b> is provided. In the substrate stage <b>600</b>, the substrate <b>500</b>, on which a substrate process using the generated neutralized beam is performed, is disposed in parallel to the substrate stage <b>600</b>. The substrate <b>500</b> comprises, for example, a semiconductor device wafer, a thin film display, or other hyperfine structure. In addition, the process performed on the substrate <b>500</b> may be an etching process.

0057Meanwhile, according to the embodiment of the present invention, the first and second ion collisions can be carried out in a single reflector unit <b>300</b> as shown in <figref idref="DRAWINGS">FIG. 4A</figref>, however, in another embodiment of the present invention, each of the first and second collisions can be carried out in separate first and second serially arranged reflector units <b>300</b> and <b>400</b> as shown in <figref idref="DRAWINGS">FIG. 4B</figref> (like reference numerals in <figref idref="DRAWINGS">FIGS. 4A</figref> and B denote like elements).

0058Referring to <figref idref="DRAWINGS">FIG. 4B</figref>, the reflector units include the first reflector unit <b>300</b>, which is adjacent to the grid unit <b>220</b> and on which the first ion collision occurs so that the ions are neutralized, and the second reflector unit <b>400</b>, which is provided at the lower part of the first reflector unit <b>300</b>, and separated from the first reflector unit <b>300</b> and within which the second collision occurs so that the incident angle of the neutralized beam is to be restored to the first ion collision angle.

0059By providing two separate reflector units <b>300</b> and <b>400</b>, ion collision occurs only a single time in a single reflector path, so that overheating of the reflector units caused by the ion collisions can be minimized. In addition, since ion neutralization is achieved in the first reflector unit <b>300</b>, in the case of the second reflector unit <b>400</b>, since ion neutralization is not necessary, it can be formed of a variety of non-metal materials such as ceramic and reinforced resin.

0060In addition, the total length of the first reflector unit <b>300</b>, on which the first collision occurs, and the second reflector unit <b>400</b>, on which the second collision occurs, can be obtained by the aforementioned mathematical equation by which the lengths of the reflectors and the widths of reflecting plates in the respective reflectors can be determined.

0061Hereinafter, a substrate processing method according to the embodiment of the present invention will be described.

0062Referring first to <figref idref="DRAWINGS">FIGS. 2 and 5</figref>, ions are extracted from an ion source <b>200</b> (S<b>10</b>). In order to extract the ions, a high-frequency power is applied to a plasma generating unit <b>210</b> in the ion source <b>200</b> so that the plasma is generated by the plasma generating unit <b>210</b>. Here, reaction gases, such as CxFy, which are required to generate the plasma, are also supplied in the plasma generating unit <b>210</b>, and the interior thereof is maintained at a pressure of about 10⁻³to 10⁻⁵torr.

0063Next, the ions are extracted from the plasma generated from the plasma generating unit <b>210</b>. The extraction of the ions is carried out in a grid unit <b>220</b>. Namely, different voltages V<b>1</b> and V<b>2</b> are respectively applied to the first and second grids <b>221</b> and <b>222</b>, so that the plasma ions are extracted based on the voltage difference (S<b>21</b>). Here, an electric potential in a range of 100 to 1,000 V can be selected based on properties of the substrate <b>500</b> undergoing processing. In addition, the extracted ions are emitted in a direction that is perpendicular to the surface of the substrate <b>500</b>.

0064The extracted ions are next neutralized to be a neutral beam, and the incident angle of the ions is restored (S<b>20</b>). In this step, the ions are first collided with the reflector at a collision angle in a range of about 3° to 10°. In this collision, the ions obtain electrons from the reflectors and are neutralized to become a neutral beam (S<b>21</b>). The neutralized beam collides a second time with the reflectors in a direction that is symmetrical with the first collision. At the second collision, the neutralized beam is restored to the original angle of incidence of the ions at the time of the first collision (S<b>22</b>). Next, the neutralized beam restored to be perpendicular to the substrate <b>500</b> arrives at the substrate <b>500</b>, so that a desired substrate process, such as an etching process, can be carried out (S<b>30</b>).

0065Accordingly, in a substrate processing apparatus using a neutralized beam and a method thereof, an incident angle of a neutralized beam is perpendicular to a substrate, while the direction of propagation of the ion source and the surface of the substrate are substantially perpendicular to each other. In this manner, the substrate processing apparatus can be placed in a perpendicular configuration, and thus there is an advantage in facilitating proper manufacturing and managing thereof. In addition, since the ion source is disposed such that the direction of propagation is perpendicular to the surface of the substrate, there is an improvement in incidence uniformity with respect to a path difference of the beam and processing uniformity at a time when the substrate processing is performed.

0066The present invention may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Namely, a shape, material, or type of the substrate of the reflector and a type, size, and constitution of the ion source can be varied according to a method that is necessary for a process. In addition, the present invention is adoptable to etching apparatus, as described above, and also to deposition apparatus and other types of substrate processing apparatus,

0067This present invention is applicable to embodiments that are implemented such that an emitting angle of the ions and an incident angle of the neutralized beam with respect to the substrate are maintained to be equal by colliding the ions 2n times (n=positive integer), and the incident angle of the neutralized beam is to be perpendicular to the surface of the substrate.

0068While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made herein without departing from the spirit and scope of the invention as defined by the appended claims.